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Buell Motorcycle Forum » Old School Buell » Archives OSB 001 » Archive through September 06, 2006 » Primary Cover Screws Rounded Out « Previous Next »

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Elmono
Posted on Monday, August 21, 2006 - 06:55 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I really don't want to use a drill on this one, any ideas? It's the four torx screws holding on the primary cover. Thanks, Chad.
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Dave
Posted on Monday, August 21, 2006 - 08:08 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Tighten the other 3 back up and work on the stubborn one.

DAve
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Spiderman
Posted on Monday, August 21, 2006 - 08:35 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Cut a slit in the head with a dremel.
Then use a small chisel to knock it loose.

Make sure you hit the head in the right direction...
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Jackbequick
Posted on Monday, August 21, 2006 - 08:56 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Actually, drilling those out is not a bad idea. Use a 1/8" (3mm) drill, then follow up with a 1/4" (6mm) drill and the heads should fall off.

Once the cover is off you can unscrew the stubs by hand or with a pliers.

There is an ideosynchracy about removing the clutch inspection covers on Buells (the one with four screws, the primary cover is what that is attached to).

If you start with the screws tightened and remove one, it will cause one or more of the other screws to jam tight, the Torx socket will probably get stripped out, and you'll be right back where you are now.

The secret is to removing the screws is that you have to break loose and remove each of the four screws loose 1/4 turn at a time, going around and around in sequence.

After you get them loose a full turn or two, you can cheat a little by pressing the cover inwards (pushing in the center of the cover to hold it in place flat against the primary) and then remove the loosened screws.

When you put the cover back, hold it flat against the primary, take the four screws down to a light touch, then go around and around tightening them 1/4 turn at a time until you reach the torque spec.

Jack

(Message edited by jackbequick on August 21, 2006)

(Message edited by jackbequick on August 21, 2006)
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